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Mercury 40 Service Manual

Mercury 40
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BIGFOOT GEAR HOUSING
Page 6B-30 90-828631R3 MARCH 1999
Reassembly
Forward Gear Bearing Race
1. Place shim(s) (retained from disassembly) into housing. If shim(s) were lost, or a new
gear housing is being assembled, start with 0.010 in. (0.254 mm) shim(s).
2. Assemble components as shown using mandrel (91-31106); Apply 2-4-C w/Teflon to
O.D. of race. Drive race into housing by striking propeller shaft end with lead hammer.
19179
b
d
e
a
c
91-31106
95
2-4-C w/Teflon (92-850736A1)
95
a-Shim(s)
b-Race
c-Mandrel (91-31106)
d-Disassembled Propeller Shaft
e-Assembled Bearing Carrier
Shift Shaft
1. Apply Loctite 271 on O.D. of new seal.
2. Press seal into shift shaft bushing until seal is seated against shoulder.
3. Install new O-ring.
4. Apply 2-4-C with Teflon on O-ring and I.D. of seal.
53930
b
c
d
7
Loctite “271” (92-809819)
7
95
2-4-C w/Teflon (92-850736A1)
95
a
a-Seal
b-Bushing
c-Surface
d-O-ring

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Mercury 40 Specifications

General IconGeneral
Horsepower40 hp
Starting SystemElectric
SteeringRemote
Fuel Induction SystemEFI (Electronic Fuel Injection)
Shaft Length20"
Full Throttle RPM Range6000

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